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BMW 328 328i 2002 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: BMW Model: 3 Series Sub Model: 328i Year: 2002 Codes Chassis Code: E46 Engine Code: M52TU B28 👋 Introduction Market Position Segment: Compact Executive Sedan/Coupe Brand Image: Performance, Luxury, Driving Dynamics Competitive Analysis Competitors: Audi A4, Mercedes-Benz C-Class, Lexus IS, Acura TL Key Features Handling: Renowned for its balanced chassis and responsive steering Powertrain: Smooth inline-six engine with ample torque Interior Design: Driver-focused cockpit, premium materials Manual Purpose Purpose: Provide detailed repair and maintenance instructions for the BMW 328i (E46) by certified technicians. 📋 Manual Details Coverage Areas Comprehensive Coverage: Yes Page Count Estimated Pages: 1500+ Manual Type Type: Service and Repair Workshop Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: Complete overhaul, diagnostics, cooling, lubrication, fuel, ignition, emissions Transmission: Manual and Automatic: Overhaul, diagnostics, fluid service, torque converter Drivetrain: Driveshaft, differential, axles, wheel bearings Suspension: Front and Rear: Struts, shocks, control arms, bushings, alignment Steering: Power steering system, steering rack, tie rods Brakes: Hydraulic system, ABS, DSC, brake pads, rotors, calipers, bleeding Electrical: Wiring diagrams, battery, alternator, starter, lighting, ECUs, sensors Bodywork: Body panels, doors, locks, windows, convertible roof (if applicable) HVAC: Air conditioning, heating, climate control systems Interior: Seats, trim, airbags, dashboard Procedures Included Maintenance: Oil changes, filter replacements, fluid checks, tune-ups, spark plugs Troubleshooting: Diagnostic procedures, fault code interpretation, common problem resolution Repair: Component replacement, system overhauls, gasket/seal replacement Diagnostics: OBD-II procedures, sensor testing, ECU diagnostics Technical Depth Depth: Full workshop level, suitable for professional mechanics and advanced DIY enthusiasts 📊 Manual Specifications File Format Searchable Text: Yes Printable Pages: Yes Print Quality Image Clarity: High Resolution Binding Type Binding Type: Digital PDF (N/A for physical) Paper Type Paper Type: Digital PDF (N/A for physical) ⚙️ Engine Specifications Primary Engine Engine Type: Naturally Aspirated Inline 6-Cylinder Displacement: 2.8 Liters (2793 cc) Bore X Stroke: 84.0 mm x 83.6 mm Compression Ratio: 10.2:1 Performance Horsepower: 193 hp @ 5500 RPM Torque: 206 lb-ft @ 3500 RPM Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (SMI) Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) Engine Management ECU Type: Bosch Motronic Variable Valve Timing: Double VANOS 🔧 Transmission Standard Type: 5-Speed Manual (Getrag 250) Optional Type: 5-Speed Automatic (Steptronic) Features Clutch Type: Hydraulic, single dry plate Fluid Specs Manual Fluid: BMW MTF LT-1 or LT-2 (refer to manual for exact spec) Automatic Fluid: ATF LT 71141 (Dexron III equivalent not always suitable) 📐 Dimensions Exterior Length: 177.4 inches (4506 mm) Width: 68.8 inches (1748 mm) Height: 56.1 inches (1425 mm) Wheelbase: 107.4 inches (2730 mm) Weights Curb Weight: 3340 lbs (1515 kg) approx. Gross Vehicle Weight Rating: 4586 lbs (2080 kg) approx. Cargo Trunk Volume: 14.1 cu ft (400 L) 🛡️ Safety Features Ratings NHTSA Front Impact: 4-Star (Driver and Passenger) IIHS Side Impact: Good (for models with side airbags) Active Features Traction Control: Dynamic Stability Control (DSC) standard Anti Lock Brakes: Anti-lock Braking System (ABS) standard Passive Features Airbags: Frontal airbags, optional front side-impact airbags Seatbelts: Pretensioner seatbelts with force limiters 💡 Technology Features Infotainment Head Unit: BMW Business CD, BMW Professional CD (optional navigation) Audio System: Harman Kardon premium audio optional Driver Assistance Cruise Control: Standard cruise control, optional adaptive cruise control (less common) Connectivity Phone Integration: Optional Bluetooth preparation, voice control (with navigation) 🔧 Maintenance Service Intervals Oil Change Interval: Condition Based Service (CBS) or 7,500-15,000 miles (consult manual) Spark Plug Replacement: Approx. 100,000 miles (NGK BKR6EQUP recommended) Coolant Flush: Every 2-4 years or 30,000-50,000 miles Fluid Specifications Engine Oil: BMW High Performance Synthetic SAE 5W-30 (e.g., BMW Longlife-01 compliant) Engine Oil Capacity: 6.9 US quarts (6.5 Liters) Coolant: BMW Blue Antifreeze/Coolant (G48) Brake Fluid: DOT 4 Known Issues Cooling System: Plastic expansion tank cracking, water pump failure (often plastic impeller) Oil Leaks: Valve cover gasket, oil pan gasket, oil filter housing gasket (O-rings) Suspension: Front control arm bushings, rear shock mounts, sway bar links Electrical: ABS/DSC wheel speed sensor failure, VANOS solenoid issues Maintenance Schedule Availability Availability: Comprehensive schedules provided for all maintenance items. 📚 Vehicle History Brand Heritage Manufacturer: Bayerische Motoren Werke AG Founded: 1916 Model Evolution Generation: E46 (Third Generation 3 Series) Production Years: 1998-2006 (E46 platform) Production Manufacturing Locations: Germany, USA (Spartanburg, SC) 🏆 Awards & Recognition Recognitions Car And Driver Ten Best: 1999-2000 (for the E46 generation overall) Ratings Jd Power Dependability: Varies by year, generally good for segment Certifications Safety Certification: DOT, NHTSA (US standards), Euro NCAP (European standards)
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BMW 328 328i 2002 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
BMW
Model:
3 Series
Sub Model:
328i
Year:
2002
Codes
Chassis Code:
E46
Engine Code:
M52TU B28
👋 Introduction
Market Position
Segment:
Compact Executive Sedan/Coupe
Brand Image:
Performance, Luxury, Driving Dynamics
Competitive Analysis
Competitors:
Audi A4, Mercedes-Benz C-Class, Lexus IS, Acura TL
Key Features
Handling:
Renowned for its balanced chassis and responsive steering
Powertrain:
Smooth inline-six engine with ample torque
Interior Design:
Driver-focused cockpit, premium materials
Manual Purpose
Purpose:
Provide detailed repair and maintenance instructions for the BMW 328i (E46) by certified technicians.
📋 Manual Details
Coverage Areas
Comprehensive Coverage:
Yes
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Service and Repair Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Complete overhaul, diagnostics, cooling, lubrication, fuel, ignition, emissions
Transmission:
Manual and Automatic: Overhaul, diagnostics, fluid service, torque converter
Drivetrain:
Driveshaft, differential, axles, wheel bearings
Suspension:
Front and Rear: Struts, shocks, control arms, bushings, alignment
Steering:
Power steering system, steering rack, tie rods
Brakes:
Hydraulic system, ABS, DSC, brake pads, rotors, calipers, bleeding
Electrical:
Wiring diagrams, battery, alternator, starter, lighting, ECUs, sensors
Bodywork:
Body panels, doors, locks, windows, convertible roof (if applicable)
HVAC:
Air conditioning, heating, climate control systems
Interior:
Seats, trim, airbags, dashboard
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks, tune-ups, spark plugs
Troubleshooting:
Diagnostic procedures, fault code interpretation, common problem resolution
Repair:
Component replacement, system overhauls, gasket/seal replacement
Diagnostics:
OBD-II procedures, sensor testing, ECU diagnostics
Technical Depth
Depth:
Full workshop level, suitable for professional mechanics and advanced DIY enthusiasts
📊 Manual Specifications
File Format
Searchable Text:
Yes
Printable Pages:
Yes
Print Quality
Image Clarity:
High Resolution
Binding Type
Binding Type:
Digital PDF (N/A for physical)
Paper Type
Paper Type:
Digital PDF (N/A for physical)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Naturally Aspirated Inline 6-Cylinder
Displacement:
2.8 Liters (2793 cc)
Bore X Stroke:
84.0 mm x 83.6 mm
Compression Ratio:
10.2:1
Performance
Horsepower:
193 hp @ 5500 RPM
Torque:
206 lb-ft @ 3500 RPM
Fuel System
Fuel Delivery:
Sequential Multi-Port Fuel Injection (SMI)
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Engine Management
ECU Type:
Bosch Motronic
Variable Valve Timing:
Double VANOS
🔧 Transmission
Standard
Type:
5-Speed Manual (Getrag 250)
Optional
Type:
5-Speed Automatic (Steptronic)
Features
Clutch Type:
Hydraulic, single dry plate
Fluid Specs
Manual Fluid:
BMW MTF LT-1 or LT-2 (refer to manual for exact spec)
Automatic Fluid:
ATF LT 71141 (Dexron III equivalent not always suitable)
📐 Dimensions
Exterior
Length:
177.4 inches (4506 mm)
Width:
68.8 inches (1748 mm)
Height:
56.1 inches (1425 mm)
Wheelbase:
107.4 inches (2730 mm)
Weights
Curb Weight:
3340 lbs (1515 kg) approx.
Gross Vehicle Weight Rating:
4586 lbs (2080 kg) approx.
Cargo
Trunk Volume:
14.1 cu ft (400 L)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4-Star (Driver and Passenger)
IIHS Side Impact:
Good (for models with side airbags)
Active Features
Traction Control:
Dynamic Stability Control (DSC) standard
Anti Lock Brakes:
Anti-lock Braking System (ABS) standard
Passive Features
Airbags:
Frontal airbags, optional front side-impact airbags
Seatbelts:
Pretensioner seatbelts with force limiters
💡 Technology Features
Infotainment
Head Unit:
BMW Business CD, BMW Professional CD (optional navigation)
Audio System:
Harman Kardon premium audio optional
Driver Assistance
Cruise Control:
Standard cruise control, optional adaptive cruise control (less common)
Connectivity
Phone Integration:
Optional Bluetooth preparation, voice control (with navigation)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Condition Based Service (CBS) or 7,500-15,000 miles (consult manual)
Spark Plug Replacement:
Approx. 100,000 miles (NGK BKR6EQUP recommended)
Coolant Flush:
Every 2-4 years or 30,000-50,000 miles
Fluid Specifications
Engine Oil:
BMW High Performance Synthetic SAE 5W-30 (e.g., BMW Longlife-01 compliant)
Engine Oil Capacity:
6.9 US quarts (6.5 Liters)
Coolant:
BMW Blue Antifreeze/Coolant (G48)
Brake Fluid:
DOT 4
Known Issues
Cooling System:
Plastic expansion tank cracking, water pump failure (often plastic impeller)
Oil Leaks:
Valve cover gasket, oil pan gasket, oil filter housing gasket (O-rings)
Suspension:
Front control arm bushings, rear shock mounts, sway bar links
Electrical:
ABS/DSC wheel speed sensor failure, VANOS solenoid issues
Maintenance Schedule Availability
Availability:
Comprehensive schedules provided for all maintenance items.
📚 Vehicle History
Brand Heritage
Manufacturer:
Bayerische Motoren Werke AG
Founded:
1916
Model Evolution
Generation:
E46 (Third Generation 3 Series)
Production Years:
1998-2006 (E46 platform)
Production
Manufacturing Locations:
Germany, USA (Spartanburg, SC)
🏆 Awards & Recognition
Recognitions
Car And Driver Ten Best:
1999-2000 (for the E46 generation overall)
Ratings
Jd Power Dependability:
Varies by year, generally good for segment
Certifications
Safety Certification:
DOT, NHTSA (US standards), Euro NCAP (European standards)
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